Ohlins RXF34 and RXF36 Air Workshop Manual

Brand: Ohlins

Model: RXF34 and RXF36 Air

Type: Workshop Manual

Workshop Manual - Chassis and Air Spring 100 h

Front Fork

RXF34/RXF36

Any reprinting or unauthorized use without the written

permission of Öhlins Racing AB is prohibited.

General Warnings

Note! 1

When working with the Öhlins product, always read the Vehicle Service Manual.

Note! 1

The shock absorber/front fork/steering damper is an important part of the vehicle

and will affect the stability.

Note! 1

Read and ensure you understand the information in this manual and other

technical documents provided by Öhlins, before using the product.

Note! 1

Öhlins Racing AB can not be held responsible for any damage to the shock

absorber/front fork/steering damper, vehicle, other property or injury to persons, if

the instructions for mounting, usage and maintenance are not followed exactly.

Warning! ⚠

After installing the Öhlins product, take a test ride at low speed to ensure your

vehicle has maintained stability.

Warning! ⚠

If the suspension makes an abnormal noise, or the function is irregular, or if you

notice any leakage from the product, stop the vehicle immediately and return the

product to an Öhlins Service Centre.

Warning! ⚠

The product warranty shall only apply if the product has been operated and

maintained in accordance with recommendations in this manual. If you have any

questions regarding usage, service, inspection and/or maintenance please contact

Öhlins.

Note! 1

Before working on the product make sure that the vehicle is washed and cleaned

properly. Do not use alcobased products on the outside or inside of the product.

Product Specic Warnings

Warning! ⚠

This product was developed and designed exclusively for a specic vehicle model

and shall only be installed on the intended vehicle model in its original condition as

delivered from the vehicle manufacturer.

Warning! ⚠

This product is pressurized. Do not open, service or modify this product without

proper education (authorized Öhlins dealer/distributor) and proper tools.

Caution! ✋

Do not use a pressure washer or a power washer when cleaning the fork.

SAFETY SYMBOLS

In this manual, mounting instructions and other technical documents,

important information concerning safety is distinguished by the following

symbols:

The Safety Alert Symbol means: Warning! Your safety is involved.

Warning! ⚠

The Warning Symbol means: Failure to follow warning instructions can result

in severe or fatal injury to anyone working with, inspecting or using the shock

absorber/front fork, or to bystanders.

Caution! ✋

The Caution Symbol means: Special precautions must be taken to avoid

damage to the shock absorber.

Note! 1

The Note Symbol indicates information that is important regarding procedures.

TABLE OF CONTENTS

Tools .......................................................................................... 3

Overview .................................................................................... 3

Service Kit Contents .................................................................. 4

Chassis 100-H Service ............................................................... 5

Air Spring Cartridge 100-H Service ............................................ 8

SAFETY PRECAUTIONS

RXF34/RXF36 100-HOUR SERVICE

Tools

3a-b

1 18860-01 Hex socket 28 mm

2 19245-01 Multi clamp TTX18

3a 19246-02 Wiper seal tool (RXF36)

3b 19246-03 Wiper seal tool (RXF34)

Overview - General layout

Chassis

Air Spring

Cartridge

Damper

Cartridge

Oil, grease, thread locker and sealant

Fork lubrication uid 01336-01 - Renep CGLP 68 Fork lube 1L

Air spring lubrication uid 01337-06 - Renep CGLP 220 Air spring lube 0.6L

Function grease 01338-22 - Renolit SI 410 M Silicone grease 225g

Assembly grease Slickoleum / Buzzy’s Slick Honey

Loctite 243 01791-03

RXF34/RXF36 100-HOUR SERVICE

Service Kit Contents

1 18850-01 Service Kit Chassis RXF34

2 18880-07 Service kit chassis SKF RXF36 *

3 18850-12 Service Kit Air Spring Cartridge RXF34/RXF36 **

*The following service kits, 18880-01/03 can also be used.

**The following service kit, 18850-02 can also be used.

18612-13

(O-ring 33x2 Blue)

18572-02

(Bump rubber)

18602-01

(Foam ring)

18579-03

(Wiper seal)

x 2 x 2 x 2

18710-01

(O-ring blue)

18572-04

(Bump rubber)

18709-01

(Foam ring)

18711-02

(Wiper seal)

x 2

18572-01

(Bump rubber)

x 2 x 2 x 2

00338-57

(O-ring)

00638-86

(O-ring)

x 2

00576-06

(O-ring)

x 2

18637-01

(O-ring Transparent)

18556-03

(Back-up ring)

18612-04

(O-ring)

RXF34/RXF36 100-HOUR SERVICE

Chassis 100-Hour Service

We recommend using a bike stand to clamp the steering tube when

working on the fork.

Note! 1

Record the rebound adjuster setting and the pressure in the positive air chamber

and ramp up chamber before service.

1. Thoroughly clean the outside of the fork from dirt or grit.

2. Release the air from the positive air chamber at the top and the

ramp up chamber at the bottom.

3. Use a 14 mm wrench to hold the rebound adjuster knob steady.

With a 2.5 mm hex key remove the screw and the knob.

4. Remove the nut by using a socket wrench with a 14 mm deep hex

socket.

5. Use a socket wrench with a 12 mm deep hex socket to remove

the washer and the nut on the lower air valve.

6. Slide the lower legs off the stanchions.

7. Drain the lower legs of all uids.

RXF34/RXF36 100-HOUR SERVICE

8. Use tweezers to cautiously remove the old foam rings in the lower

legs.

9. Carefully remove the old bump rubbers from the lower legs.

Protect lowers and seal surfaces from scratches.

10. Use a screwdriver or similar to remove the old wiper seals.

11. Use a rag wrapped around a long rod or similar to clean the

insides of the lower legs.

Note! 1

Be careful not to scratch the bushings.

12. Carefully clean the wiper seal and foam ring areas using disc

brake cleaner and a paper cloth or rag to remove old suspension

uid and dirt.

13.

Reinsert new bump rubbers (18572-02 RXF34, 18572-01 RXF36)

into the lower legs. Use a long rod or similar to carefully put them in

place.

RXF34/RXF36 100-HOUR SERVICE

14. Reinsert new wiper seals (18579-03 RXF34, 18711-01/18711-02

RXF36) into the lower legs. Use the wiper seal tool and a soft ham

mer to put them in place.

15. Apply a thin layer of functional grease to the inner surfaces of

the wiper seals.

16. Soak the foam rings in fresh fork lubrication uid.

17. Use tweezers or similar to carefully reinsert the soaked foam

rings into the lower legs. Check that they are mounted corrrectly and

not twisted.

18. Remove the old sag o-ring.

19. Install a new sag o-ring (18612-13 RXF34, 18710-01 RXF36)

from the service kit.

RXF34/RXF36 100-HOUR SERVICE

Air Spring Cartridge 100-Hour Service

Note! 1

Clean all parts using disc brake cleaner and a rag to remove dirt, old grease and

thread sealant before reassembling. Lubricate new o-rings/x-rings etc. with fresh

Assembly grease.

Note! 1

Use a vise and the appropriate shaft clamps when servicing the front fork.

1. Remove the positive air chamber knob. Use a socket wrench with

a hex socket 28 mm (18860-01) to loosen the air spring.

Caution! ✋

Do not use an adapter between wrench and socket, as this will increase the risk of

damaging the anodized nish of the top cap.

Note! 1

When removing the Air Spring cartridge, it is easy to damage the Top Cap. Put

pressure on the wrench while unthreading the Top Cap.

2. Slide the air spring off the stanchion tube.

3. Use a 19 mm wrench to loosen the seal head. Slide the cylinder

tube off the air spring.

4. Remove the old o-ring (00576-06) from the top cap.

5. Clean top cap threads (male and female) using a rag covered by

degreaser or brake cleaner. Use a nylon bristled brush to remove

any remaining residue from threads.

Note! 1

Do not use alcohol: alcohol reacts and causes damage to the seals.

Important!

Make sure any old Loctite is removed.

6. Install a new o-ring (00576-06) on the top cap.

RXF34/RXF36 100-HOUR SERVICE

7. Remove the old o-ring (18612-04) from the base cap.

8. Install a new o-ring (18612-04) on the base cap.

9. Remove the two old o-rings (00638-86) from the upper air

chamber cylinder tube.

10. Install two new o-rings (00638-86) on the upper air chamber

cylinder tube. Apply assembly grease on o-rings.

11. Remove the old o-ring (18637-01) from the piston.

RXF34/RXF36 100-HOUR SERVICE

12. Remove the the two old back-up rings (18556-03).

13. Carefully clean the piston using disc brake cleaner and a paper

cloth or rag to remove old grease and dirt.

14. Install a new o-ring (18637-01) on the piston between the back-

up rings.

15. Install two new back-up rings (18556-03) on the piston.

16. Apply 2 ml of function grease at the inside of the cylinder

tube (smeared around). Add 0,5 ml of air spring lubrication uid

distributed on top of the grease.

RXF34/RXF36 100-HOUR SERVICE

17. Reinstall the stanchion tubes into the lower legs.

18. Inject 5 ml of fork lubrication uid in spring fork leg and 5 ml in

damper fork leg. Tighten both nuts to 10 Nm.

19. Reinstall the rebound adjuster nut, knob and screw.

Ret the lower valve nut and washer.

20. Inate the ramp up chamber (A) at the bottom and then the

positive air chamber (B) at the top to the desired air pressures.

Caution! ✋

Inate the ramp up chamber (A) at the bottom rst.

5 ml

RXF34/RXF36 100-HOUR SERVICE

17. Slide the upper air chamber cylinder tube onto the lower air

spring assembly and add 0,5 ml of air spring lubrication uid insi

de the cylinder tube. screw the seal head and cylinder tube together

to hand-tight. Then use a 19 mm torque wrench to tighten the seal

head to 10 Nm.

18. Reinstall the Air spring cartridge into the stanchion tube.

19. Apply blue Loctite 243 to the rst (lower) two (2) threads of the

top cap (male).

20. Use a torque wrench with a 28 mm hex socket (18860-01) to

tighten the top cap to 32 Nm.

Caution! ✋

Do not use an adapter between wrench and socket, as this will increase the risk of

damaging the anodized nish of the top cap.

21. Wipe off eventual excessive Loctite 243.

Important!

Leave the Loctite to cure for 24 hours before riding.

22. Processed with 100h damper service to compleate lower leg

assembly.

32 Nm

Your Öhlins retailer:

Phone: +46 (0)8 590 025 00

Fax: +46 (0)8 590 025 80

www.ohlins.com

Öhlins Racing AB

Box 722

SE-194 27, Upplands Väsby

Sweden

Ohlins RXF34 and RXF36 Air Workshop Manual

Ohlins RXF34 and RXF36 Air Workshop Manual

Ohlins RXF34 and RXF36 Air Workshop Manual

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